System and method for filling containers with liquid under varying pressure conditions

Abstract

A system and method for filling a container such as a syringe or vial with liquid is provided. Also provided is a system and method for closing a filled container with a stopper or piston gas-pocket free. The systems and methods are carried out at a minimum of two different pressure levels to provide filled and / or closed containers substantially without formation of gas pockets or foaming in the container. Also provided is a system and method for degassing liquid useful in the filling and closing processes.

Description

FIELD OF INVENTION [0001] The present invention relates to systems and methods for filling containers with liquids, and more particularly to processes for filling containers at different pressure levels, such that the containers are filled substantially without formation of gas pockets or foaming. BACKGROUND OF THE INVENTION [0002] Industrial applications frequently require containers to be filled using dedicated processes in order to fulfill special product or process requirements. Filling processes for liquids include standard processes carried out in many industries. Traditionally, it has been difficult to fill containers without including gas pockets. [0003] Different dosing systems can be used for filling containers, including time pressure filling, peristaltic pumps, rotational piston pump systems, and other conventional filling arrangements. Some filling processes use vacuum to improve the process. Closing systems sometimes use vacuum to reduce the volume of enclosed gas in t...

AI Technical Summary

Benefits of technology

[0016] According to the above-described systems and methods for filling and closing containers substantially without formation of gas pockets or foaming, standard dosing systems can be used to provide accurate dosing volumes in standard cycle times. One advantage of the filling process is that in a subsequent closing process, during evacuation for piston setting, there is no eruption in the liquid, even when this evacuation is accomplished very quickly and the pressure level is low. Another advantage of the invention is that liquids that tend to create foam can also be filled under a plurality of different pressure levels.

[0017] A system for degassing a liquid can include a pressure vessel enclosing a soft bag, the pressure vessel being regulated to at least two different pressure levels, a liquid source for supplying a predetermined dose of liquid to the soft bag, and a vacuum pump connected to the pressure vessel for providing vacuum to inside of the pressure vessel, wherein the vacuum reduces the pressure in the soft bag and causes gas to separate from degassed liquid in the soft bag, the separated gas being removable upon raising the pressure in the soft bag.

[0018] A method for degassing a liquid can include steps of: providing a pressure vessel enclosing a soft bag, the pressure vessel being regulated to at least two different pressure levels, supplying a portion of a predetermined dose of liquid to the soft bag, applying vacuum to the pressure vessel to reduce the pressure in the soft bag and causing gas to separate from degassed liquid in the soft bag, supplying a remainder of the predetermined dose of liquid to the soft bag; and removing the separated gas from the soft bag.

[0019] Other aspects and embodiments of the invention are discussed below.

Problems solved by technology

Traditionally, it has been difficult to fill containers without including gas pockets.

However, this process would not be effective with low viscosity liquids because applying vacuum during piston setting would lead to eruption of the liquid.

Moreover, during filling, the application of high vacuum would result in inaccurate dose volumes.

At least two major problems occur during filling and closing of containers containing liquids.

First, the filling process often lacks accuracy.

The requirement of high vacuum during stopper setting is another negative impact.

Second, gas may be trapped in the cone or the needle of the syringe by capillary force.

This trapped gas will expand rapidly during evacuation for stopper setting, which can lead to eruptions in the syringe that wet the glass and the piston area, with a negative impact on quality.

Another problem with conventional filling technology is the tendency of some liquids to create a large amount of foam during the filling process.

Foaming can disturb the closing process and result in product loss when the foam passes over the top of a vial or syringe.

Additional problems with foaming include sterility, difficulty of inspection, and lack of cleanliness.

Exposing the tank to more than one connection is undesirable, because it may lead to loss of sterility or product loss.

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